Coating layer removal method and coating layer removal device
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2026-02-03
- Publication Date
- 2026-08-13
Smart Images
Figure JP2026003709_13082026_PF_FP_ABST
Abstract
Description
Method for removing a coating layer and apparatus for removing a coating layer
[0001] The present invention relates to a method for removing a coating layer and an apparatus for removing a coating layer.
[0002] In recent years, from the perspective of protecting Earth's resources and the environment, there has been a growing movement in various fields to build a circular economy through efforts such as reducing waste generation, reusing waste, and recycling waste. For example, Patent Document 1 discloses a method for recycling plastic products having a painted film, characterized by peeling off the painted film formed on the plastic body with a high-pressure water jet, and then crushing and recycling the plastic body. Patent Document 2 discloses a winding diameter control device for a shaft-driven winding machine, characterized in that, when tension control is performed, a PID calculator that calculates the winding diameter using signals from a speed detector proportional to the speed of the material being wound and a speed detector proportional to the rotation of the winding shaft outputs a signal in one direction toward the winding thickness side, and this signal is provided to a tension calculation circuit and a speed calculation circuit, and the tension calculation circuit and the speed calculation circuit are switched by a switching circuit.
[0003] JP-A-5-269743 JP-A-5-015191
[0004] In the technology of removing a coating layer from a laminated film by roll-to-roll, the laminated film may break during conveyance. The breakage of the laminated film is more likely to occur when using a laminated film for a specific purpose. For example, a laminated film provided for the production of a multilayer ceramic capacitor (MLCC) has a structure in which breakage is more likely to occur when a so-called half cut is performed, in which a punching blade cuts into the middle of the thickness of the laminated film beyond the thickness of the ceramic green sheet. Also, for the removal of the coating layer, it is desirable to use water in terms of reducing the environmental load. In the method described in Patent Document 1, the coating film can be peeled off from the plastic body by spraying high-pressure jet water onto the coating film surface. However, the technology described in Patent Document 1 is not a technology that employs roll-to-roll. In the shaft-driven winding device that performs tension control described in Patent Document 2, when the winding material breaks during operation, the calculated winding diameter (calculated winding diameter) is controlled so as not to move from the thick side to the thin side of the winding, but no consideration is given to preventing the breakage of the winding material itself.
[0005] An object of the present invention is to provide a method and an apparatus for removing a coating layer that can suppress breakage of a laminated film in a technology of removing a coating layer from a laminated film by roll-to-roll.
[0006] [1] A method for removing a coating layer, comprising the steps of: preparing a laminated film roll around which a laminated film having a base film and a coating layer is wound; unwinding the laminated film from the laminated film roll; winding and transporting the laminated film in the order of a first peripheral speed control roller, a spray backup roller, and a second peripheral speed control roller; spraying water onto the coating layer to remove the coating layer when the laminated film passes the spray backup roller; and recovering the base film after the coating layer has been removed by winding it into a roll, wherein the peripheral speed FR of the first peripheral speed control roller and the peripheral speed RR of the second peripheral speed control roller are adjusted so that the tension T1 applied to the laminated film transported between the unwinding section of the laminated film roll and the first peripheral speed control roller is greater than the tension T2 applied to the laminated film transported between the first peripheral speed control roller and the second peripheral speed control roller. [2] The method for removing a coating layer according to [1], wherein the first peripheral speed control roller is a first nip roller or a first suction roller, and the laminated film is wrapped around the first nip roller or the first suction roller and conveyed downstream. [3] The method for removing a coating layer according to [1], wherein the first peripheral speed control roller is a first nip roller, and the laminated film is conveyed downstream by passing between the first nip roller and a first backup roller facing the first nip roller. [4] The method for removing a coating layer according to [1], wherein the second peripheral speed control roller is a second nip roller or a second suction roller, and the laminated film is wrapped around the second nip roller or the second suction roller and conveyed downstream. [5] The method for removing a coating layer according to [1], wherein the second peripheral speed control roller is a second nip roller, and the laminated film is conveyed downstream by passing between the second nip roller and a second backup roller facing the second nip roller.[6] The method for removing a coating layer according to any one of [1] to [5], wherein the base film has a first base surface on which the coating layer is provided and a second base surface opposite to the first base surface, the coating layer has a plurality of recesses, and notches are formed from the end faces of the recesses toward the base film, the notches do not reach the second base surface. [7] The method for removing a coating layer according to any one of [1] to [6], wherein the coating layer includes a release agent layer. [8] The method for removing a coating layer according to [7], wherein the coating layer includes a ceramic green sheet. [9] A coating layer removal apparatus for removing a coating layer from a laminated film having a base film and a coating layer, comprising: a feed shaft for feeding the laminated film from a laminated film roll in which the laminated film is wound in a roll shape; a first peripheral speed control roller disposed downstream of the feed shaft for transporting the laminated film downstream; a spray backup roller disposed downstream of the first peripheral speed control roller for transporting the laminated film downstream; a spray unit including one or more nozzles disposed opposite the spray backup roller for spraying water onto the coating layer from the one or more nozzles so as the laminated film passes the spray backup roller to remove the coating layer; a water supply unit for supplying water to the spray unit; a second peripheral speed control roller disposed downstream of the spray backup roller for transporting the laminated film downstream; and a winding shaft for winding the base film in a roll shape after the coating layer has been removed. A coating layer removal device comprising: a tension setting unit that sets tensions T1 and T2 such that the tension T1 applied to the laminated film conveyed between the feed shaft and the first peripheral speed control roller is higher than the tension T2 applied to the laminated film conveyed between the first peripheral speed control roller and the second peripheral speed control roller; the water supply unit includes a pump; and the spray unit is connected to the pump.
[10] The tension setting unit includes a peripheral speed control unit that controls the peripheral speed FR of the first peripheral speed control roller and the peripheral speed RR of the second peripheral speed control roller, and the peripheral speed control unit is connected to the first peripheral speed control roller and the second peripheral speed control roller, the coating layer removal device according to [9].
[0007] According to one aspect of the present invention, a method for removing a coating layer from a laminated film using a roll-to-roll method, and an apparatus for removing a coating layer that can suppress the tearing of the laminated film, can be provided.
[0008] A cross-sectional view of a first example of a laminated film used in the removal method according to the first embodiment. A perspective view of a second example of a laminated film used in the removal method according to the first embodiment. A cross-sectional view of the laminated film as seen from line X-X in Figure 2. A schematic diagram of an example of a removal device according to the second embodiment. A schematic diagram of an example of a removal device according to the third embodiment. A schematic diagram of an example of a removal device according to the fourth embodiment.
[0009] In this specification, ordinal numbers such as "first" and "second" are used to distinguish components and do not indicate order. In this specification, expressions without ordinal numbers, such as "peripheral speed control roller," are a general term for peripheral speed control rollers and are used when describing peripheral speed control rollers that have ordinal numbers such as "first" and "second." For example, when a description is made that applies to multiple components that are indicated with ordinal numbers, such as "first peripheral speed control roller" and "second peripheral speed control roller," the "first peripheral speed control roller" and "second peripheral speed control roller" are expressed collectively by omitting the ordinal number and simply writing "peripheral speed control roller."
[0010] [First Embodiment] [Method for Removing the Coating Layer] The method for removing the coating layer according to this embodiment (hereinafter also referred to as the removal method according to this embodiment) comprises the steps of: preparing a laminated film roll around which a laminated film having a base film and a coating layer is wound; unwinding the laminated film from the laminated film roll; winding and conveying the laminated film in the order of a first peripheral speed control roller, a spray backup roller, and a second peripheral speed control roller; spraying water onto the coating layer to remove the coating layer when the laminated film passes the spray backup roller; and recovering the base film after the coating layer has been removed by winding it into a roll. The peripheral speed FR of the first peripheral speed control roller and the peripheral speed RR of the second peripheral speed control roller are adjusted so that the tension T1 applied to the laminated film conveyed between the unwinding section of the laminated film roll and the first peripheral speed control roller is greater than the tension T2 applied to the laminated film conveyed between the first peripheral speed control roller and the second peripheral speed control roller. The removal method according to this embodiment is carried out roll-to-roll.
[0011] In this embodiment, when removing the coating layer from a laminated film using the impact pressure of water in a roll-to-roll manner, it is believed that the removal efficiency can be improved by increasing the impact pressure of water on the coating layer and increasing the transport speed of the laminated film. However, increasing the impact pressure of water on the coating layer or increasing the transport speed of the laminated film makes the laminated film more prone to meandering during transport. On the other hand, in order to suppress the meandering of the laminated film, it is necessary to increase the tension applied to the laminated film during transport, but simply increasing the tension has the problem that the laminated film becomes more prone to breakage. Furthermore, there is also the problem that breakage of the laminated film is more likely to occur when using laminated films that have been used for a specific purpose. For example, laminated films supplied for the manufacture of multilayer ceramic capacitors (MLCCs) have a so-called half-cut structure in which cuts are made partway through the thickness. When water is sprayed onto the coating layer (i.e., the side with the half-cut cuts) of such a laminated film while tension is applied to it, the cuts become the starting point, making the laminated film more prone to breakage. Therefore, in the removal method according to this embodiment, a first peripheral speed control roller and a second peripheral speed control roller are arranged upstream and downstream of the spray backup roller, respectively, and the peripheral speeds of these peripheral speed control rollers are adjusted so that the tension T1 > the tension T2 relationship. In other words, the tension applied to the laminated film is adjusted before and after water is sprayed onto the coating layer of the laminated film. As a result, when water is sprayed onto the coating layer, the tension applied to the laminated film is adjusted to be low, and the coating layer is removed in this state (removal step). In the removal step, the effect of the impact pressure of water on the coating layer can be suppressed, so even if water is sprayed onto areas that were conventionally the starting point of breakage (for example, half-cut areas with notches), the laminated film is less likely to break. According to the removal method according to this embodiment, breakage of the laminated film can be suppressed in a roll-to-roll technique for removing the coating layer from a laminated film.Furthermore, according to the removal method of this embodiment, since it uses virtually only water without using chemicals, there is no need to treat wastewater containing chemicals, which can keep wastewater treatment costs low and also reduce the impact on the global environment.
[0012] <Laminated Film> Figure 1 is a cross-sectional view of a first example of a laminated film used in the removal method according to the first embodiment. The laminated film 90 has a base film 91 and a coating layer 92. The base film 91 has a first base surface 91a on which the coating layer 92 is provided, and a second base surface 91b opposite to the first base surface 91a. The base film 91 and the coating layer 92 are directly laminated. In the laminated film 90, it is preferable that the coating layer 92 includes a release agent layer. In the case of Figure 1, the coating layer 92 is a release agent layer. The coating layer 92 may also include a ceramic green sheet, as shown in Figure 2.
[0013] Figure 2 is a perspective view of a second example of a laminated film used in the removal method according to the first embodiment. Figure 3 is a cross-sectional view taken along line X-X in Figure 2. Figure 2 shows a laminated film supplied for the manufacture of a multilayer ceramic capacitor (MLCC), in which a ceramic green sheet has been removed along a cut. The laminated film 90A is wound around a core 1G to form a roll (laminated film roll). An insertion hole 2G is provided in the central part of the core 1G. The laminated film 90A has a base film 91 and a coating layer 92A. The coating layer 92A includes a release agent layer 921 and a ceramic green sheet 922 (residue) from the side of the base film 91. The base film 91 and the release agent layer 921 are directly laminated, and the release agent layer 921 and the ceramic green sheet 922 are directly laminated. The ceramic green sheet 922 is partially provided on the surface of the release agent layer 921. The surface of the laminated film 90A is cut in two parts: the outer periphery and the center. The center is peeled off and supplied for the manufacture of the MLCC, while the outer periphery remains to form a ceramic green sheet 922. The center of the laminated film 90A supplied for the manufacture of the MLCC is a recess 930, from which the release agent layer 921 is exposed. The recess 930 has a total of four end faces 930a in the length direction (conveying direction) and width direction of the laminated film 90A. The half-cut structure will be explained with reference to Figure 3. The coating layer 92A has a plurality of recesses 930. Figure 3 shows two of the four end faces 930a of the recess 930 in the length direction of the laminated film 90A. Cuts 94 are formed from these two end faces 930a in the length direction toward the base film 91. In Figure 3, these cuts 94 penetrate the release agent layer 921 and reach partway through the base film 91, but do not reach the second base surface 91b of the base film 91. The same applies to the two end faces 930a in the width direction of the laminated film 90A as to the two end faces 930a in the length direction. In the laminated film 90A, the ceramic green sheet 922 may be a green sheet composed of a dielectric as an active ingredient.The ceramic green sheet 922 may be a multilayer including, from the side of the release agent layer 921, a green sheet composed of a dielectric as an active ingredient and a conductive layer (not shown) composed of a conductor as an active ingredient. A green sheet is an unfired sheet-like material, and a green sheet with ceramics as an active ingredient is called a ceramic green sheet.
[0014] Each step of the removal method according to this embodiment will be described.
[0015] <Preparation Process, Unwinding Process> The preparation process involves preparing a laminated film roll on which a laminated film having a base film and a coating layer is wound. The unwinding process involves unwinding the laminated film from the laminated film roll. The dimensions of the laminated film are, for example, a width of 100 mm or more and 1000 mm or less, preferably 200 mm or more and 600 mm or less. The length of the laminated film is, for example, 50 m or more and 30000 m or less, preferably 100 m or more and 10000 m or less. The winding diameter of the laminated film roll (the diameter of the roll including the core) is, for example, 100 mm or more and 1500 mm or less, preferably 150 mm or more and 1000 mm or less.
[0016] <Conveying Process> The conveying process involves winding the laminated film onto a first peripheral speed control roller, a spray backup roller, and a second peripheral speed control roller in that order for conveyance. Examples of the first and second peripheral speed control rollers include a nip roller and a suction roller. A suction roller is a roller that has numerous intake holes on its surface, and conveys the material by drawing air in through these intake holes to attract the material to the roller surface, holding the material in place while the roller rotates. Known rollers can be used as suction rollers. Known rollers used as ordinary backup rollers can be used as spray backup rollers. During normal operation, excluding the start and end of the conveying process, the peripheral speed FR of the first peripheral speed control roller and the peripheral speed RR of the second peripheral speed control roller are adjusted so that the tension T1 applied to the laminated film conveyed between the laminated film roll feed section and the first peripheral speed control roller is greater than the tension T2 applied to the laminated film conveyed between the first peripheral speed control roller and the second peripheral speed control roller (satisfying the relationship T1 > T2). The units of tension T1 and tension T2 are [N]. The relationship T1 > T2 is achieved, for example, by making the peripheral speed FR of the first peripheral speed control roller faster than the peripheral speed RR of the second peripheral speed control roller.
[0017] The peripheral speed FR of the first peripheral speed control roller and the peripheral speed RR of the second peripheral speed control roller are set, for example, by the following method: (Method 1) The tension T1 and T2 are measured by controlling the feed speed, winding speed, peripheral speed FR of the first peripheral speed control roller, and peripheral speed RR of the second peripheral speed control roller. By operating the actual laminated film and the actual device in this way and obtaining data in advance, a combination of conditions (peripheral speed FR and peripheral speed RR) that can obtain the target tension T1 and T2 (tension T1 > tension T2) is found. Then, the actual device is operated using the actual laminated film with the found combination of peripheral speed FR and peripheral speed RR. As the device, for example, the removal device of the second embodiment can be used. (Method 2) While operating the actual apparatus using an actual laminated film, the tensions T1 and T2 are measured, and the peripheral speed FR of the first peripheral speed control roller and the peripheral speed RR of the second peripheral speed control roller are controlled so that the relationship T1 > T2 is maintained. For example, a peripheral speed control unit (e.g., a computer) sets the peripheral speed FR of the first peripheral speed control roller and the peripheral speed RR of the second peripheral speed control roller, respectively, based on the measured tensions T1 and T2, so that the relationship T1 > T2 is maintained. As the apparatus, for example, the removal apparatus of the third and fourth embodiments can be used.
[0018] The tension T1 is, for example, 3N or more and 50N or less, more preferably 5N or more and 50N or less. The tension T2 is, for example, 1N or more and 50N or less, more preferably 3N or more and 30N or less. The ratio of the difference between tension T1 and tension T2 [(tension T1 - tension T2) / tension T2 × 100] is, for example 0.1 or more and 50 or less, more preferably 1 or more and 30 or less. The tension T1 and tension T2 are measured, for example, by a known tension measuring instrument. The tension measuring instrument for measuring tension T1 is placed between the feed section of the laminated film roll and the first peripheral speed control roller. The tension measuring instrument for measuring tension T2 is placed between the first peripheral speed control roller and the second peripheral speed control roller, preferably between the spray backup roller and the second peripheral speed control roller.
[0019] The peripheral speed FR of the first peripheral speed control roller is, for example, 1 m / min or more and 300 m / min or less, more preferably 3 m / min or more and 250 m / min or less. The peripheral speed RR of the second peripheral speed control roller is, for example, 0.5 m / min or more and 300 m / min or less, more preferably 1 m / min or more and 200 m / min or less. The ratio of the difference between the peripheral speed FR and the peripheral speed RR [(peripheral speed FR - peripheral speed RR) / peripheral speed RR × 100] is, for example, 0.1 or more and 30 or less, more preferably 0.5 or more and 10 or less.
[0020] (First peripheral speed control roller) In one embodiment of the conveying process, the first peripheral speed control roller is a first nip roller, and the laminated film is conveyed downstream by passing between the first nip roller and a first backup roller facing the first nip roller. In one embodiment of the conveying process, the first peripheral speed control roller is a first nip roller or a first suction roller, and the laminated film is wrapped around the first nip roller or the first suction roller and conveyed downstream.
[0021] (Second peripheral speed control roller) In one embodiment of the conveying process, the second peripheral speed control roller is a second nip roller, and the laminated film is conveyed downstream by passing between the second nip roller and a second backup roller facing the second nip roller. In one embodiment of the conveying process, the second peripheral speed control roller is a second nip roller or a second suction roller, and the laminated film is wrapped around the second nip roller or second suction roller and conveyed downstream.
[0022] <Removal Process> In the removal process, water is sprayed onto the coating layer as the laminated film passes through the spray backup roller to remove the coating layer. The water used in the removal process is sprayed toward the coating layer and used to remove the coating layer. The water is preferably ordinary water, i.e., industrial water, and may be purified water or distilled water. It may also be recycled wastewater used in various industrial productions, or recycled wastewater after it has been used in the implementation of this embodiment. If wastewater is recycled, it may be treated to regenerate the wastewater as appropriate. From the viewpoint of improving work efficiency, the water may contain additives that add functionality as appropriate, but it is preferable not to include them. Examples of additives include surfactants and water-soluble organic solvents. If the water contains additives, the concentration of the active ingredients of the additives in the water is preferably 0.2% by mass or less, more preferably 0.1% by mass or less, relative to the total amount of water, and furthermore, it is preferable that the water is not water to which additives have been intentionally added. Furthermore, it is preferable that the water is neither an alkaline aqueous solution prepared by intentionally adding a basic substance nor an acidic aqueous solution prepared by intentionally adding an acidic substance. Since wastewater can potentially be treated with simple recycling processes, the water may contain basic and acidic substances as additives, but in that case, it is preferable that the pH of the water be between 5.8 and 8.6 in accordance with the uniform wastewater discharge standards (other items) based on the Water Pollution Control Law. The temperature of the water used is preferably room temperature, and it may be cold water or warm water.
[0023] In this specification, the water pressure when spraying water onto the coating layer refers to the nozzle pressure (the water pressure applied to the nozzle outlet). In the removal step, the nozzle pressure is, for example, 3.0 MPa or more and 70 MPa or less, more preferably 10 MPa or more and 50 MPa or less. The removal step is preferably a step of spraying water toward the coating layer of the laminated film while the laminated film is supported by a spray backup roller. In this case, the removal step is preferably a step of spraying water toward the coating layer of the laminated film from one or more nozzles positioned opposite the spray backup roller while the spray backup roller is in contact with the second substrate surface 91b (Figure 1) of the base film.
[0024] <Process of circulating to a pump> The removal method according to this embodiment preferably includes a step of filtering the water containing the coating layer removed in the removal step and circulating it to a pump. The means for filtering the water containing the coating layer is, for example, a filter. It is preferable that the water circulated to the pump be reused as water used in the removal step.
[0025] <Draining Process> The removal method according to this embodiment preferably includes a step of draining the water from the base film after the removal process and before the base material recovery process. The draining process is, for example, a step of removing residue from the base film. Residue refers to, for example, the coating layer remaining on the base film, as well as water and foreign matter adhering to the base film. The means of draining the water are not particularly limited, but examples include a draining nozzle (also called an air knife) and a dryer.
[0026] <Substrate Recovery Process> In the substrate recovery process, the substrate film is recovered by known methods.
[0027] [Second Embodiment] [Coating Layer Removal Apparatus] In the second embodiment, the X-axis, Y-axis, and Z-axis are orthogonal to each other, the X-axis and Y-axis are axes in a predetermined plane, and the Z-axis is an axis orthogonal to the predetermined plane. Furthermore, in the second embodiment, when directions are indicated based on the view from the front direction of Figure 4, which is parallel to the Y-axis, "up" is the direction of the Z-axis arrow and "down" is the opposite direction, "right" is the direction of the X-axis arrow and "left" is the opposite direction, "front" is the front direction of Figure 3, which is parallel to the Y-axis and "back" is the opposite direction. Also, in Figure 4, the side closer to the feed shaft 10 is called the "upstream side", and the side closer to the winding shaft 40 is called the "downstream side".
[0028] Figure 4 is a schematic diagram of the coating layer removal device 100 according to the second embodiment. The removal device 100 is a roll-to-roll device that removes the coating layer from a laminated film having a base film and a coating layer. In the second embodiment, an example of removing the coating layer 92 from the laminated film 90 shown in Figure 1 using the removal device 100 will be described.
[0029] The removal device 100 according to the second embodiment includes a feed shaft 10 that feeds out the laminated film 90 from a laminated film roll in which the laminated film is wound in a roll shape, a first peripheral speed control roller 81 positioned downstream of the feed shaft 10 and transporting the laminated film downstream, a spray backup roller 20 positioned downstream of the first peripheral speed control roller 81 and transporting the laminated film downstream, and one or more nozzles positioned opposite the spray backup roller 20, and the one or more nozzles that spray the coating layer to remove the coating layer as the laminated film passes over the spray backup roller 20. The device comprises an injection unit 31 for injecting water into the coating layer, a water supply unit 50 for supplying water to the injection unit 31, a second peripheral speed control roller 82 positioned downstream of the injection backup roller 20 for transporting the laminated film downstream, a winding shaft 40 for winding the base film 91 after the coating layer has been removed into a roll, and a tension setting unit 80 for setting tensions T1 and T2 such that the tension T1 applied to the laminated film transported between the feed shaft 10 and the first peripheral speed control roller 81 is higher than the tension T2 applied to the laminated film transported between the first peripheral speed control roller 81 and the second peripheral speed control roller 82. The water supply unit 50 includes a pump (in the case of Figure 4, a supply pump 62), and the injection unit 31 is connected to the pump. The removal device 100 also comprises a water recovery and regeneration device 60, a residue removal device 70, and a plurality of guide rollers GR. Known rollers can be used as the guide rollers GR.
[0030] The removal device 100 according to the second embodiment includes a tension setting unit 80, which adjusts the tension T1 to be greater than the tension T2. This adjusts the tension applied to the laminated film to be lower when water is sprayed onto the coating layer from one or more nozzles positioned opposite the spray backup roller 20. As a result, the effect of water impact on the coating layer is mitigated, and the rupture of the laminated film is suppressed. Furthermore, according to the removal device 100 according to the second embodiment, even when a laminated film with a structure that is more prone to rupture (for example, a laminated film provided for the manufacture of MLCCs) is used, the rupture of the laminated film is suppressed.
[0031] The components of the removal device 100 according to the second embodiment will now be described.
[0032] <Feeding shaft 10> The feeding shaft 10 feeds out the laminated film 90 from the laminated film roll, which is wound in a roll shape. The feeding shaft 10 is connected to a drive roller (not shown).
[0033] <First peripheral speed control roller 81, second peripheral speed control roller 82> In the second embodiment, the first peripheral speed control roller 81 is a first nip roller, and the laminated film 90 is conveyed downstream by passing between the first nip roller and a first backup roller 83 facing the first nip roller. The second peripheral speed control roller 82 is a second nip roller, and the laminated film 90 is conveyed downstream by passing between the second nip roller and a second backup roller 84 facing the second nip roller. The peripheral speed FR of the first peripheral speed control roller and the peripheral speed RR of the second peripheral speed control roller are set by the tension setting unit 80.
[0034] <Tension Setting Unit 80> The tension setting unit 80 sets the tension T1 and the tension T2 such that the tension T1 is higher than the tension T2. In the second embodiment, the tension setting unit 80 includes a first tension measuring instrument 801A, a second tension measuring instrument 802A, guide rollers GR arranged upstream and downstream of the tension measuring instruments 801A and 802A, respectively, peripheral speed control rollers 81 and 82, and backup rollers 83 and 84. The tension measuring instruments 801A and 802A are known tension measuring instruments.
[0035] In the case of Figure 4, the tension setting unit 80 finds the peripheral speed FR of the first peripheral speed control roller 81 and the peripheral speed RR of the second peripheral speed control roller 82 in the following manner. The following method is an example of (Method 1) described in the first embodiment. The laminated film 90 and the removal device 100 are operated, and the unwinding speed, winding speed, peripheral speed FR of the first peripheral speed control roller, and peripheral speed RR of the second peripheral speed control roller are controlled to measure the tension T1 and tension T2 in advance using the first tension measuring instrument 801A and the second tension measuring instrument 802A. Based on the measured values obtained in advance (unwinding speed, winding speed, peripheral speed FR, and peripheral speed RR), the tension setting unit 80 finds a combination of peripheral speed FR and peripheral speed RR that satisfies the relationship T1 > T2 and is suitable for other operating conditions. Then, the removal device 100 is operated with the found combination of peripheral speed FR and peripheral speed RR. Note that the tension setting unit 80 in the second embodiment does not include a peripheral speed control unit. Other embodiments of the tension setting unit that include a peripheral speed control unit, unlike the tension setting unit 80 in the second embodiment, will be described in the third and fourth embodiments.
[0036] <Injection section 31> The injection section 31 includes one or more nozzles positioned opposite the injection backup roller 20. When the laminated film 90 passes over the injection backup roller 20, water is injected from one or more nozzles onto the coating layer 92 to remove the coating layer 92 of the laminated film 90. In the injection section 31, from the viewpoint of applying water impact pressure to the surface of the coating layer 92, it is preferable that the central axes of the one or more nozzles in the injection section 31 are perpendicular to the tangent to the outer circumference of the injection backup roller 20 when viewed in a cross-section perpendicular to the central axis 20a of the injection backup roller 20. The injection section 31 is located inside the injection chamber 301 and is configured so that the injected water is guided to the tank 53 of the water recovery and regeneration device 60. The nozzle shape is not particularly limited, but it is preferable that it be a flow-constricting nozzle. A flow-constricting nozzle is a nozzle that ejects water from a constricted outlet, such as an orifice and a flow nozzle. When the nozzle is a flow-constricting nozzle, the inner diameter of the nozzle outlet is the inner diameter of the constricted section. The nozzle pattern is not particularly limited, but examples include a flat pattern (spraying in a fan shape from the nozzle), a full cone pattern (spraying in a cone shape from the nozzle), and a straight pattern (spraying in a linear shape from the nozzle). Among these, a flat pattern is preferred. In roll-to-roll applications, a flat pattern can break down and remove the coating layer with fewer nozzles and less water compared to a straight pattern.
[0037] <Water Supply Unit 50> The water supply unit 50 pressurizes water and supplies pressurized water W2 to the injection unit 31. The water supply unit 50 includes a supply pump 62, and the injection unit 31 is connected to the supply pump 62. The water supply unit 50 is, for example, a known pressurized water generator. The water supply unit 50 comprises a water source 55, a tank 53 for storing water W1, piping 54 connecting the water source 55 and the tank 53, and a supply pump 62. The supply pump 62 is connected to the injection unit 31 via piping 531. The tank 53 stores water supplied from the water source 55 and water recycled by the water recovery and recycling device 60. In the water supply unit 50, the water W1 stored in the tank 53 is used when generating pressurized water. The supply pump 62 pressurizes the water W1 and supplies pressurized water W2 to the injection unit 31.
[0038] <Water Recovery and Recycling Device 60> The water recovery and recycling device 60 separates water from the coating layer (detached material) by passing the water ejected from the injection unit 31 through a filtration filter 71. The water recovery and recycling device 60 comprises a tank 53, a filtration filter 71, and a recovery pump 61 positioned between the tank 53 and the filtration filter 71.
[0039] <Residue Removal Device 70> The residue removal device 70 is a device that removes residue adhering to the base film 91, and is an example of a means for dewatering the base film. The residue removal device 70 is located downstream of the spray backup roller 20 and upstream of the winding shaft 40. Residue refers to, for example, the coating layer 92 remaining on the base film 91, as well as water and foreign matter adhering to the base film 91. The residue removal device 70 is not particularly limited, but for example, the aforementioned means for dewatering can be cited. In the case of Figure 4, the residue removal device 70 is a pair of dewatering nozzles.
[0040] <Winding shaft 40> The winding shaft 40 is located downstream of the injection backup roller 20 and winds the base film into a roll after the coating layer has been removed. The winding shaft 40 is connected to a drive roller (not shown).
[0041] [Third Embodiment] [Coating Layer Removal Apparatus] The coating layer removal apparatus 101 according to the third embodiment will be described below. In the third embodiment, the differences from the second embodiment will be described in detail, and explanations of similar matters will be omitted or simplified by using the same reference numerals. Figure 5 is a schematic diagram of the removal apparatus 101 according to the third embodiment. The removal apparatus 101 according to the third embodiment has the same configuration as the second embodiment, except that it is equipped with a tension setting unit 80A instead of the tension setting unit 80 in Figure 4.
[0042] <Tension Setting Unit 80A> The tension setting unit 80A includes a first tension measuring instrument 801A, a second tension measuring instrument 802A, guide rollers GR positioned upstream and downstream of the tension measuring instruments 801A and 802A, peripheral speed control rollers 81 and 82, backup rollers 83 and 84, and a peripheral speed control unit 800. The peripheral speed control unit 800 controls the peripheral speed FR of the first peripheral speed control roller 81 and the peripheral speed RR of the second peripheral speed control roller 82.
[0043] (Peripheral speed control unit 800) The peripheral speed control unit 800 is connected to the first peripheral speed control roller 81 and the second peripheral speed control roller 82, and controls the peripheral speed FR of the first peripheral speed control roller 81 and the peripheral speed RR of the second peripheral speed control roller 82. The peripheral speed control unit 800 is, for example, a computer. It is preferable that the peripheral speed control unit 800 is connected to the tension measuring instruments 801A and 802A.
[0044] In the case of FIG. 5, the tension setting unit 80A sets the peripheral speed FR of the first peripheral speed control roller 81 and the peripheral speed RR of the second peripheral speed control roller 82 as follows. The following method is an example of (Method 2) described in the first embodiment. The peripheral speed control unit 800 sets the peripheral speed FR of the first peripheral speed control roller 81 and the peripheral speed RR of the second peripheral speed control roller 82 based on the tension T1 and the tension T2 measured by the first tension measuring device 801A and the second tension measuring device 802A, while satisfying the relationship of the tension T1 > the tension T2, and drives the peripheral speed control rollers 81 and 82 at the set peripheral speeds, respectively. The peripheral speed control unit 800 sets the optimal tension T1 and tension T2 among this relationship (tension T1 > tension T2) according to the specific device structure and size, and the physical properties of the laminated film, etc.
[0045] 〔Fourth Embodiment〕 〔Coating Layer Removal Device〕 The coating layer removal device 102 according to the fourth embodiment will be described. In the fourth embodiment, the description will focus on the differences from the third embodiment, and for the description of the same matters, the same reference numerals will be used, etc., and the description will be omitted or simplified. FIG. 6 is a schematic diagram of the removal device 102 according to the fourth embodiment. The removal device 102 according to the fourth embodiment has the same configuration as the third embodiment except that it includes a tension setting unit 80B instead of the tension setting unit 80A in FIG. 5.
[0046] <Tension Setting Unit 80B> The tension setting unit 80B includes a single first peripheral speed control roller 81A instead of the first peripheral speed control roller 81 and the first backup roller 83 in the third embodiment. The first peripheral speed control roller 81A is a first suction roller. By using the first suction roller, the following effects can be achieved. Tension can be controlled without a backup roller. By not using a backup roller, the degree of freedom in the design of the pass line can be increased. In the removal device 102, the peripheral speed control unit 800 controls the peripheral speed FR of the first peripheral speed control roller 81A and the peripheral speed RR of the second peripheral speed control roller 82 in the same manner as in the third embodiment.
[0047] [Modifications of Embodiments] The present invention is not limited to the above embodiments. The present invention can include modifications, improvements, etc. within the scope that can achieve the object of the present invention. The removing devices of the second to fourth embodiments may be provided with a residual detection device downstream of the backup roller for injection and upstream of the winding shaft. The residual detection device is a device for detecting the residue of the coating layer, for example, a thickness gauge for measuring the film thickness of the coating layer. Further, the residual detection device may have not only a function of detecting the residue of the coating layer but also a foreign matter detection function. In the third and fourth embodiments, for example, the peripheral speed control unit 800 may be changed to a control means other than a computer (including operations by an operator). In the second to fourth embodiments, the first peripheral speed control roller and the second peripheral speed control roller may each be a single suction roller. The first peripheral speed control roller and the second peripheral speed control roller may be of the same type combination or different from each other.
[0048] The configuration of the laminated film will be described.
[0049] [Laminated Film] The laminated film used in the above-described embodiments has a base film and a coating layer. The coating layer may be a single layer or a multilayer composed of two or more coating layers of the same or different types. From the viewpoint of facilitating the removal of the coating layer from the laminated film and recovering the remaining base film, it is preferable that the base film and the coating layer are directly laminated. Here, "directly laminated" refers to a configuration in which, for example, the base film and the coating layer are in direct contact with each other without having another layer therebetween.
[0050] <Base Film> The base film used is a resin film on which the resin component intended for recovery has been formed. Suitable resin films include polyester films such as polyethylene terephthalate film, polybutylene terephthalate, and polyethylene naphthalate; polyolefin films such as polyethylene film and polypropylene film; polyimide film; polyamide film; polycarbonate film; polyacetate film; ethylene-vinyl acetate copolymer (EVA) film; ethylene-(meth)acrylic acid copolymer film; ethylene-(meth)acrylic acid ester copolymer film; cycloolefin polymer film; polyurethane film; polyphenylene sulfide film; cellophane; and others. Among the base films, polyester film is preferred due to its excellent heat resistance and strength. As for polyester films, polyester films with polyethylene terephthalate, polybutylene terephthalate, and polyethylene naphthalate as the main constituent component are preferred from the viewpoint of facilitating resin recovery and regeneration. In this specification, the main constituent component or principal component means that the proportion of the total mass of the material is 50% by mass or more. Furthermore, the resin film may contain known fillers, colorants, antistatic agents, antioxidants, organic lubricants, and catalysts. The resin film may be transparent or colored as desired. In addition, at least one surface of the base film may be subjected to surface treatment such as sputtering, corona discharge, flame, ultraviolet irradiation, electron beam irradiation, and oxidation etching as needed.
[0051] There are no particular restrictions on the thickness of the base film, but from the viewpoint of strength, rigidity, etc., it is preferably 10 μm to 500 μm, more preferably 15 μm to 300 μm, and even more preferably 20 μm to 200 μm.
[0052] <Coating Layer> The coating layer is preferably a functional layer. Examples of functional layers include a release agent layer, an intermediate layer, a printing layer, a hard coat layer, an easy-adhesion layer, and an adhesive layer. The coating layer may include a functional layer and a ceramic green sheet, or a functional layer, a ceramic green sheet, and a conductive layer. The coating layer preferably includes at least a release agent layer.
[0053] (Release Agent Layer) When the coating layer is a release agent layer, it is preferable that the release agent layer is formed from a release agent composition. The release agent composition used to form the release agent layer is not particularly limited as long as it has release properties, and for example, release agent compositions mainly composed of silicone compounds, fluorine compounds, long-chain alkyl group-containing compounds, thermoplastic resin materials such as olefin resins and diene resins can be used. It is also preferable to use a release agent composition mainly composed of an energy ray curable or thermosetting resin. These release agent compositions may be used individually or in combination of two or more.
[0054] In a release agent composition mainly composed of a silicone compound, the silicone compound may include a silicone compound having an organopolysiloxane as its basic structure. Other examples of the silicone compound include thermosetting silicone compounds such as addition reaction type and condensation reaction type; and energy ray curing silicone compounds such as ultraviolet curing type and electron beam curing type.
[0055] In a release agent composition mainly composed of a fluorine compound, examples of the fluorine compound include fluorosilicone compounds, fluoroboron compounds, and poly(perfluoroalkylene ether) chain-containing compounds.
[0056] In a release agent composition mainly composed of a long-chain alkyl group-containing compound, examples of the long-chain alkyl group-containing compound include polyvinyl carbamate obtained by reacting a long-chain alkyl isocyanate with a polyvinyl alcohol polymer, alkylurea derivatives obtained by reacting a long-chain alkyl isocyanate with polyethyleneimine, or copolymers of long-chain alkyl (meth)acrylates. Furthermore, a long-chain alkyl-modified alkyd resin obtained by a condensation reaction of a polyhydric alcohol and a polybasic acid, using a long-chain fatty acid as a modifying agent, may also be used.
[0057] Preferably, the release agent composition mainly composed of an energy-ray curable resin contains, for example, an energy-ray curable compound having a reactive functional group selected from a (meth)acryloyl group, an alkenyl group, and a maleimide group, and a polyorganosiloxane. In the release agent layer formed by this release agent composition, since the energy-ray curable compound and the polyorganosiloxane have different molecular structures, polarities, and molecular weights, components derived from the polyorganosiloxane segregate near the outer surface of the release agent layer before curing, and then the segregation is fixed by curing with energy rays. This improves the release properties of the release agent layer. The release agent composition mainly composed of an energy-ray curable resin may further contain a photopolymerization initiator.
[0058] Examples of release agent compositions mainly composed of thermosetting resins include release agent compositions mainly composed of melamine resin and release agent compositions mainly composed of epoxy resin. Examples of release agent compositions mainly composed of melamine resin include a composition containing melamine resin as the main component, an acid catalyst for thermosetting the melamine resin, and a polyorganosiloxane that imparts release properties to the release agent layer. Examples of release agent compositions mainly composed of epoxy resin include a composition containing epoxy resin as the main component, an acid or basic thermosetting catalyst for thermosetting the epoxy resin, and a polyorganosiloxane that imparts release properties to the release agent layer. Before curing, components derived from polyorganosiloxane segregate near the outer surface of the release agent layer, and then the segregation is fixed after curing. This improves the release properties of the release agent layer.
[0059] Furthermore, the coating layer may contain other additives in addition to the resin components mentioned above. Examples of other additives include anti-aging agents, light stabilizers, flame retardants, conductive agents, antistatic agents, and plasticizers.
[0060] The thickness of the coating layer can be selected as appropriate and is not particularly limited, but for example, it is preferably 0.02 μm to 5 μm, more preferably 0.03 μm to 2 μm, and even more preferably 0.05 μm to 1.5 μm.
[0061] (Ceramic Green Sheet) The coating layer preferably includes a release agent layer and a ceramic green sheet. In this case, the laminated film preferably has the base film, the release agent layer, and the ceramic green sheet directly laminated in this order.
[0062] A ceramic green sheet can be obtained, for example, by coating the surface of a coating layer opposite the substrate film with a ceramic slurry, and then drying the ceramic slurry. Coating can be performed using, for example, a slot die coating method or a doctor blade method. The ceramic slurry contains ceramic powder, a binder component, and a solvent. Examples of ceramic powders include dielectric powders such as barium titanate, titanium oxide, alumina, zirconia, zinc oxide, aluminum silicate, and silicon nitride. When dielectric powder is used as the ceramic powder, a green sheet used in the manufacture of multilayer ceramic capacitors (MLCCs) can be obtained (specifically, a green sheet composed of dielectric as the active ingredient). The ceramic powder may also be a ceramic powder other than a dielectric. The thickness of the ceramic green sheet is, for example, 0.1 μm to 10 μm.
[0063] (Conductive layer) When the coating layer includes a release agent layer, a ceramic green sheet, and a conductive layer, it is preferable that the laminated film is directly laminated in this order: the base film, the release agent layer, the ceramic green sheet, and the conductive layer. The conductive layer is not particularly limited, and a conductive layer used in the manufacture of electronic components can be used. The conductive layer is formed on the ceramic green sheet, for example, by applying a conductive paste. The thickness of the conductive layer is, for example, 0.1 μm or more and 5 μm or less.
[0064] (Intermediate layer) The coating layer may include a release agent layer and an intermediate layer. In this case, it is preferable that the intermediate layer and the release agent layer are directly laminated in this order from the base film side. Alternatively, the coating layer may be directly laminated with the intermediate layer, release agent layer and ceramic green sheet in this order from the base film side. Or, the coating layer may be directly laminated with the intermediate layer, release agent layer, ceramic green sheet and conductive layer in this order from the base film side. Examples of intermediate layers include a water-soluble intermediate layer, an alkali-degradable intermediate layer, and a layer that is hydrophilic and water-insoluble.
[0065] (Water-soluble intermediate layer) When the intermediate layer is a water-soluble intermediate layer, examples of water-soluble resins included in the intermediate layer include water-soluble polyvinyl alcohol resin, water-soluble acrylic resin, water-soluble polyester resin, water-soluble polyester urethane resin, water-soluble ethylene ionomer resin, water-soluble polyvinylpyrrolidone resin, water-soluble poly-N-vinylacetamide resin, water-soluble polyamide resin, water-soluble ethylene-vinyl alcohol resin, and water-soluble starch. The content of water-soluble resin in the intermediate layer is preferably 30% by mass or more and 90% by mass or less, and more preferably 40% by mass or more and 80% by mass or less, based on the total mass of the intermediate layer. The upper limit of the content of water-soluble resin in the intermediate layer is 100% by mass.
[0066] (Alkali-degradable intermediate layer) When the intermediate layer is an alkali-degradable intermediate layer, examples of alkali-degradable resins included in the intermediate layer include phenolic resin, polyacrylic acid, polyamide resin, polyester resin, and polylactic acid. The content of alkali-degradable resin in the intermediate layer is preferably 30% by mass or more and 90% by mass or less, and more preferably 40% by mass or more and 80% by mass or less, based on the total mass of the intermediate layer. The upper limit of the content of water-soluble resin in the intermediate layer is 100% by mass.
[0067] (Hydrophilic and water-insoluble layer) When the intermediate layer is a hydrophilic and water-insoluble layer, it is preferable that the intermediate layer is made of a silane compound that exhibits polycondensation by hydrolysis, from the viewpoint of more easily separating the coating layer from the substrate film side surface of the intermediate layer.
[0068] When the intermediate layer is hydrophilic and water-insoluble, the silane compound is preferably a tetraalkoxysilane. More preferred specific examples of the tetraalkoxysilane include tetramethoxysilane, tetraethoxysilane, tetrapropoxysilane, and tetrabutoxysilane. Among these, from the viewpoint of ease of availability and reactivity of the hydrolysis reaction, at least one of tetramethoxysilane and tetraethoxysilane, or a mixture of tetramethoxysilane and tetraethoxysilane, is preferred. Commercially available products can also be used as the hydrolysis polycondensate of the silane compound.
[0069] When the intermediate layer contains a hydrophilic and water-insoluble resin (preferably the silane compound), the content of the hydrophilic and water-insoluble resin is preferably 30% to 90% by mass, and more preferably 40% to 80% by mass, relative to the total mass of the intermediate layer. The upper limit for the content of the hydrophilic and water-insoluble resin in the intermediate layer is 100% by mass.
[0070] The thickness of the intermediate layer is preferably 0.01 μm to 1 μm, more preferably 0.03 μm to 0.5 μm, and even more preferably 0.05 μm to 0.3 μm, from the viewpoint of facilitating moisture penetration when the intermediate layer comes into contact with water.
[0071] The laminated films used in each embodiment are generally used to protect the surfaces of other functional sheets and various components used for specific applications during manufacturing, transportation, and storage. After fulfilling their protective role, they are often peeled off the surface and discarded. Therefore, by using the laminated film, the coating layer and the base film can be easily separated from the laminated film, making it a highly beneficial application from the standpoint of resource conservation and environmental protection.
[0072] 10...feeding shaft, 20...backup roller for spraying, 20a...central axis, 31...spraying section, 40...winding shaft, 50...water supply section, 53...tank, 54...piping, 55...water source, 60...water recovery and recycling device, 61...recovery pump, 62...supply pump, 70...residue removal device, 71...filtration filter, 800...peripheral speed control unit, 80, 80A, 80B...tension setting unit, 81, 81A, 82...peripheral speed control roller, 83, 84...backup roller, 90, 90A...laminated film, 91...base film, 92, 92A...coating layer, 94...cut, 100, 101, 102...removal device, 301...spraying chamber, 531...piping, 801A, 802A...tension measuring instrument, 921...release agent layer, 922...ceramic green sheet, 930a...end face.
Claims
1. A method for removing a coating layer, comprising the steps of: preparing a laminated film roll around which a laminated film having a base film and a coating layer is wound; unwinding the laminated film from the laminated film roll; winding and transporting the laminated film in the order of a first peripheral speed control roller, a spray backup roller, and a second peripheral speed control roller; spraying water onto the coating layer to remove the coating layer as the laminated film passes the spray backup roller; and recovering the base film after the coating layer has been removed by winding it into a roll, wherein the peripheral speed FR of the first peripheral speed control roller and the peripheral speed RR of the second peripheral speed control roller are adjusted so that the tension T1 applied to the laminated film transported between the unwinding section of the laminated film roll and the first peripheral speed control roller is greater than the tension T2 applied to the laminated film transported between the first peripheral speed control roller and the second peripheral speed control roller.
2. The method for removing a coating layer according to claim 1, wherein the first peripheral speed control roller is a first nip roller or a first suction roller, and the laminated film is wrapped around the first nip roller or the first suction roller and conveyed downstream.
3. The method for removing a coating layer according to claim 1, wherein the first peripheral speed control roller is a first nip roller, and the laminated film is conveyed downstream by passing between the first nip roller and a first backup roller facing the first nip roller.
4. The method for removing a coating layer according to claim 1, wherein the second peripheral speed control roller is a second nip roller or a second suction roller, and the laminated film is wrapped around the second nip roller or the second suction roller and conveyed downstream.
5. The method for removing a coating layer according to claim 1, wherein the second peripheral speed control roller is a second nip roller, and the laminated film is conveyed downstream by passing between the second nip roller and a second backup roller facing the second nip roller.
6. The method for removing a coating layer according to any one of claims 1 to 5, wherein the base film has a first base surface on which the coating layer is provided and a second base surface opposite to the first base surface, the coating layer has a plurality of recesses, and cuts are formed from the end faces of the recesses toward the base film, and the cuts do not reach the second base surface.
7. The method for removing a coating layer according to claim 1, wherein the coating layer includes a release agent layer.
8. The method for removing a coating layer according to claim 7, wherein the coating layer includes a ceramic green sheet.
9. A coating layer removal apparatus for removing a coating layer from a laminated film having a base film and a coating layer, comprising: a feed shaft for feeding the laminated film from a laminated film roll in which the laminated film is wound in a roll shape; a first peripheral speed control roller disposed downstream of the feed shaft for transporting the laminated film downstream; a spray backup roller disposed downstream of the first peripheral speed control roller for transporting the laminated film downstream; a spray unit including one or more nozzles disposed opposite the spray backup roller for spraying water onto the coating layer from the one or more nozzles so as the laminated film passes the spray backup roller to remove the coating layer; a water supply unit for supplying water to the spray unit; a second peripheral speed control roller disposed downstream of the spray backup roller for transporting the laminated film downstream; and a winding shaft for winding the base film in a roll shape after the coating layer has been removed. A coating layer removal device comprising: a tension setting unit that sets tensions T1 and T2 such that the tension T1 applied to the laminated film conveyed between the feed shaft and the first peripheral speed control roller is higher than the tension T2 applied to the laminated film conveyed between the first peripheral speed control roller and the second peripheral speed control roller; the water supply unit includes a pump; and the spray unit is connected to the pump.
10. The coating layer removal apparatus according to claim 9, wherein the tension setting unit includes a peripheral speed control unit that controls the peripheral speed FR of the first peripheral speed control roller and the peripheral speed RR of the second peripheral speed control roller, and the peripheral speed control unit is connected to the first peripheral speed control roller and the second peripheral speed control roller.